Patent Application
20150375182
This invention relates to the field of mixing fluids and more particularly to a system for mixing fluids that set quickly.
Many fluids need to be mixed well before applying, for example, when spraying on a surface for rigidity or for affixing the surface to another surface in which the fluids are multiple parts of an adhesive. Many such fluids are very viscous (thick). For example, a resin and a catalyst are often very viscous, especially the resin. Likewise, a typical adhesive and hardener such as a two part epoxy is also viscous. A mix of polyurea and isocyanate as a catalyzer are often mixed before applying.
The properties and applications for such materials and many other fluid materials require that the materials be mixed just before application. For many materials, mixing before application is possible due to both the reaction during mixing and the amount of time before the mixture sets (e.g. hardens). For example, some epoxy adhesives set on the order of one hour after being mixed. Many of these materials are mixed in batches before applying.
The properties and applications for some materials require that the fluids be mixed almost instantaneously before application to the target surface. In some cases, setting completes within several seconds of mixing. If such fluids are mixed in a batch, the batch would set before application is complete. In some cases, the mixing of the fluids causes a reaction as with polyurethane/urea foams (commonly known as polyurethane foam. The reaction of, for example, isocyanates and water forms carbamic acid that quickly decomposes, splitting off carbon dioxide and leaving behind an amine. In such, the carbon dioxide provides the foaming action. If this mixing is performed in a batch, the foam would occur in the mixing vat, requiring large amounts of space to contain the foam.
Some prior spray gun systems mixed two or more fluids within the spray gun just before forcing the combined fluid out of a nozzle. Such in-line mixing works for certain fluids, especially low viscosity fluids that readily mix, perhaps in the nozzle, but mixing some fluids in this manner results in uneven mixing, especially high viscosity fluids, resulting in almost separate streams of each fluid exiting the nozzle and mixing partially at the target surface.
Some prior mixing systems such as disclosed in U.S. Pat. No. 7,744,019 to Merchant, include a turbulent flow chamber of considerable length. These mixers repeatedly split the materials, and then fold the mix onto itself. In U.S. Pat. No. 7,744,019, the spiral mixer is a reversely flighted segmented pattern with each segment being reversely flighted from adjacent segments. This pattern allows homogenous mixing of a catalyst and resin as they pass through a mixing tube. This reference discloses that the tube and spiral mixer are preferably made of an inexpensive plastic so that after spraying, catalyzed resin both can be discarded, as some of the catalyst and resin will set (harden) within the tube and mixer. Due to the length of travel of the fluids, some of the fluids that mix very at an early point in these types of mixers often begin to set before exiting the mixer, causing clogs and wear downstream in the mixer and nozzle.
What is needed is a system that will properly mix two or more fluids in a minimal distance, hence reducing time.
In one embodiment, a collider mixer is disclosed including a collider mixer element that has a plurality of partitions. The partitions form channels around the collider mixer element between an input port that is fluidly coupled to a first channel and an output port that is fluidly coupled to a last channel. Inter-partition passages are formed in each of the partitions for passing the fluid from one channel to an adjacent channel. A mixing chamber surrounds the partitions of the collider mixer such that outer edges of the partitions abut inside walls of the mixing chamber, enclosing the channels. Fluids entering the input port split and a first portion of the fluids flow in one direction through each channel and a remaining second portion of the fluids flow in an opposite direction through the channel The first portion of the fluids and the second portion of the fluids meet and collide at the inter-partition passages, where the fluids recombine and pass through the inter-partition passage to an adjacent channel.
In another embodiment, a method of mixing two or more fluids is disclosed including (a) partially pre-mixing the fluids then (b)
splitting the fluids into two separate flows of the fluids, a first flow and a second flow. The first flow is collided with the second flow which is repeated as many times as needed to mix the fluids to the desired level of mixing.
In another embodiment, a collider mixer is disclosed including a collider mixer element having a cylindrical shape and having plurality of cylindrical partitions. The cylindrical partitions form cylindrical channels around the collider mixer element. An input port is fluidly coupled to a first cylindrical channel and an output port is fluidly coupled to a last cylindrical channel. Exactly one inter-partition passage is formed/cut in each of the partitions and a mixing chamber that has a cylindrical inner surface matching an outer cylindrical surface of the cylindrical partitions holds the mixing chamber such that outer edges of the cylindrical partitions seal with the inner surface of the mixing chamber, thereby enclosing the cylindrical channels. Fluids enter the input port and split. A first portion of the fluids flow one direction through each cylindrical channel and a remaining second portion of the fluids flow in an opposite direction through the same cylindrical channel. The first portion of the fluids and the second portion of the fluids meet and collide at the inter-partition passages, where the first portion of the fluids recombine with the second portion of the fluids and then pass through the inter-partition passage to an adjacent cylindrical channel.
The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.
Throughout this description, the collider mixer apparatus is described mixing two fluids such as a resin and a catalyst or an adhesive and a catalyzer, etc., for example purposes only as it is fully anticipated that any number of fluids are mixed by the collider mixer apparatus having two or more input orifices.
Referring to
The opposing side of the collider mixing element 10 has similar inter-partition passages 16 so that, on one side of the collider mixing element 10, inter-partition passages 16 permit passage of fluid between odd partitions 18 and on the opposite side of the collider mixing element 10, inter-partition passages 16 permit passage of fluid between even partitions 18. In this way, the combined fluids enter the collider mixing element 10 through an input orifice 14 and approximately half of the fluids go around the collider mixing element 10 in a clockwise direction and the remainder of the fluids go around the collider mixing element 10 in a counterclockwise direction, meeting on the distal opposite side of the collider mixing element 10 where the two flows (clockwise flow and counterclockwise flow) collide and mix. The mixed/blended flows then transition through the inter-partition passage 16 (on the opposite side, not visible in
Note that any length, dimension, and/or number of partitions 18 are anticipated providing any required number of collisions as to provide the needed degree of mixing. Also, although in the embodiments shown, the inter-partition passages 16 on alternating partitions 18 are located approximately 180 degrees apart around the collider mixing element 10, any arrangement of inter-partition passages 16 is anticipated. For example, it is equally anticipated that the second inter-partition passages 16 is positioned at approximately 150 degrees around the collider mixing element 10. In this way, the fluid traveling in one direction around the collider mixing element 10 must travel further than the fluid traveling in the opposite direction around the collider mixing element 10 and, therefore, different portions of the fluids will mix at the collision.
Also note that, although the spacing between partitions 18 is shown as being the same between all partitions 18, any spacing between partitions 18 is equally anticipated, forming larger or smaller channels between certain partitions 18 affects flow rates and collision actions.
Also note that, although the outer shape of the collider mixer 10 and the inner shape of the mixing chamber 44 are substantially cylindrical, any shape is anticipated.
Holes 50 bored through the base 44 of the housing 40 are provided for attaching to an up-stream device 80 (see
Referring to
In use, a down-stream device such as a nozzle is removably affixed over the exit surface 32 by, for example, a threaded fastener that holds the down-stream device (not shown) in contact with the exit surface 32, thereby receiving the mixed fluids from the exit bore 30. For cleaning, the down-stream device is removed and the collider mixing element 10 is removed from the mixing chamber 44, providing access to most surfaces for cleaning, for example, with solvents and air streams.
Referring to
In these views, the sequencing of inter-partition passages 16 is clear, showing the upper inter-partition passages 16 on odd number partitions 18 (from the left) and the lower inter-partition passages 16 on even number partitions 18. Again, adjacent inter-partition passages 16 are shown offset from each other by 180 degrees as an example, and any offset is anticipated.
Although two fluids are shown being mixed as an example, any number of fluids is anticipated. The fluids are provided under pressure from an up-stream device 80 such as a dispensing gun or other valve assembly for control of the flow of the fluids. The fluids preferably pass through check valves 60/62/64 to prevent any of the fluids from back-flowing into the up-stream device 80, potentially clogging that device 80. In this example, the check valve comprises a spring 62 that biases a ball 64 against a surface of the up-stream device 80, such that, fluid pressure from the up-stream device 80 works against the spring 62, thereby allowing flow from the up-stream device 80 into the housing 40, while pressure on the fluids within the housing 40 work with the spring 62, preventing flow of fluids from the housing 40 back into the up-stream device 80. Removable fasteners 60 hold the spring 62 in place and are removed for cleaning of the housing 40, springs 62, and balls 64.
Although generally required only for production, cover screws 66 and set screws 70 seal production holes used during manufacture. During manufacturing, in some embodiments, the first input channels 72 are formed by drilling from where the cover screws 66 are shown, before the cover screws 66 are installed. Likewise, the second input channels 74 are formed by drilling from where the set screws 70 are shown, before the set screws 70 are installed.
A first fluid flows from the up-stream device 80 around the upper ball 64, through the upper first channel 72, through the upper second channel 74 and into a space between a back surface of the collider mixing element 10 and an inner-most surface of the mixing chamber 40. A second fluid flows from the up-stream device 80 around the lower ball 64, through the lower first channel 72, through the lower second channel 74 and into the same space between a back surface of the collider mixing element 10 and an inner-most surface of the mixing chamber 40. The first fluid and the second fluid partially mix in the space between a back surface of the collider mixing element 10 and an inner-most surface of the mixing chamber 40 before entering the collider mixing element 10 through a mixer channel 17, then out the input orifice 14, splitting and traveling between the first two partitions 18, etc.
Referring to
Referring to
Referring to
Note that various aspects of the disclosed embodiments, various specific shapes, sizes, and appendages are shown that relate to one specific method of manufacturing the collider mixer, but such disclosure is not provided to limit the claims in any way as other methods of manufacturing are equally anticipated.
Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result.
It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.
